Systems and methods for manufacturing polymer components using a slurry

Abstract

Systems and methods for forming a slurry and manufacturing a part with the slurry are disclosed. The slurry may comprise a solvent, a polymer soluble in the solvent, and additives insoluble in the solvent. The polymer may be dissolved in the solvent such that the slurry has a lower viscosity than a viscosity of the polymer, which may enable the slurry to flow and be utilized by a manufacturing device. Once manufactured, the solvent may be removed from the slurry material, and the manufactured part may have the original viscosity of the polymer.

Having thus described various embodiments of the present disclosure, what is claimed as new and desired to be protected by Letters Patent includes the following: 
     
         1 . A system for manufacturing polymer parts via additive manufacturing, the system comprising:
 a slurry comprising a solvent, one or more additives that are insoluble in the solvent, and an elastomer that is soluble in the solvent, the elastomer having a first viscosity,   wherein the solvent dissolves the elastomer to form the slurry having a second viscosity lower than the first viscosity,   wherein a ratio of the solvent to the elastomer in the slurry is in a range of 3:2 to 4:1;   a manufacturing device that manufactures a part with the slurry, the manufacturing device comprising:
 a build surface configured to receive the slurry; and 
 a print head comprising a nozzle and configured to extrude the slurry through the nozzle onto the build surface to manufacture the part; and 
   a curing device operable at a pressure below atmospheric pressure, the curing device comprising:   a heated chamber encompassing at least a portion of the manufacturing device, the heated chamber configured to heat the part to remove the solvent such that at least a portion of the part has the first viscosity.   
     
     
         2 . The system of  claim 1 , wherein the one or more additives are electrically conductive. 
     
     
         3 . The system of  claim 1 , wherein the elastomer has a hardness scale durometer value of at least 15 Shore D. 
     
     
         4 . The system of  claim 1 ,
 wherein the elastomer comprises at least one of a vinyl copolymer elastomer, ethylene-vinyl acetate, polyvinyl chloride, polyvinyl alcohol, or polyvinyl ether,   wherein the solvent comprises tetrahydrofuran.   
     
     
         5 . The system of  claim 1 , wherein the slurry is a first slurry and further comprising:
 a second slurry distinct from the first slurry, wherein the part is formed from the first slurry and the second slurry.   
     
     
         6 . The system of  claim 1 , wherein the slurry comprises at least 10 percent by weight of the one or more additives. 
     
     
         7 . The system of  claim 1 , wherein the elastomer comprises a synthetic rubber. 
     
     
         8 . A system for manufacturing polymer parts, comprising:
 a slurry comprising a solvent, an elastomer having a first viscosity, and one or more additives,   wherein the solvent dissolves the elastomer to form the slurry having a second viscosity lower than the first viscosity;   an additive manufacturing device comprising:
 a build surface for receiving the slurry; and 
 a print head comprising a nozzle for selectively extruding the slurry onto the build surface to form a part; and 
   a heated chamber encompassing at least a portion of the additive manufacturing device and operable at a pressure below atmospheric pressure, the heated chamber configured to heat the part to a temperature above room temperature to remove the solvent such that at least a portion of the part has the first viscosity,   wherein the part comprises the elastomer and the one or more additives.   
     
     
         9 . The system of  claim 8 , wherein a ratio of the solvent to the elastomer in the slurry is within a range of 3:2 to 3:1. 
     
     
         10 . The system of  claim 8 , further comprising a mixer configured to form the slurry by mixing the solvent, the elastomer, and the one or more additives. 
     
     
         11 . (canceled) 
     
     
         12 . The system of  claim 8 , wherein the slurry comprises at least 10 percent by weight of the one or more additives. 
     
     
         13 . The system of  claim 12 , wherein at least one of the one or more additives are electrically conductive and insoluble in the solvent. 
     
     
         14 . The system of  claim 8 , wherein the part has the first viscosity. 
     
     
         15 . A method for manufacturing polymer parts, the method comprising:
 forming a slurry by combining a solvent, an elastomer that is soluble in the solvent and has a first viscosity, and one or more additives that are insoluble in the solvent,   wherein the slurry has a second viscosity lower than the first viscosity;   extruding the slurry via a nozzle of an additive manufacturing device onto a build surface of the additive manufacturing device to form a part; and   providing heat to the part via a curing device to remove the solvent from the part such that at least a portion of the part has the first viscosity,   wherein the curing device encompasses at least a portion of the additive manufacturing device,   wherein the curing device is operated at a pressure below atmospheric pressure.   
     
     
         16 . The method of  claim 15 , further comprising:
 perforating a surface of the part via a needle to remove at least a portion of the solvent from the part.   
     
     
         17 . The method of  claim 15 ,
 wherein a ratio of the solvent to the elastomer in the slurry is within a range of 3:2 to 3:1,   wherein the slurry comprises at least 10 percent by weight of the one or more additives.   
     
     
         18 . The method of  claim 15 ,
 wherein the elastomer comprises at least one of a vinyl copolymer elastomer, an ethylene-vinyl acetate, a polyvinyl chloride, a polyvinyl alcohol, or a polyvinyl ether,   wherein the solvent comprises tetrahydrofuran.   
     
     
         19 . The method of  claim 15 , wherein the elastomer has a hardness scale durometer value of at least 30 Shore A. 
     
     
         20 . The method of  claim 15 , further comprising:
 perforating a surface of the part to facilitate removal of the solvent from the part.   
     
     
         21 . The system of  claim 8 , further comprising a needle configured to perforate a surface of the part.